Hindawi Publishing Corporation

Journal of ermodynamics
Volume 2014, Article ID 863408, 7 pages
http://dx.doi.org/10.1155/2014/863408

Research Article
Performance Evaluation of Refrigeration Units in
Natural Gas Liquid Extraction Plant

Awajiogak Anthony Ujile and Dirina Amesi

Department of Chemical/Petrochemical Engineering, Faculty of Engineering, Rivers State University of Science and Technology,
PMB 5080, Port Harcourt 50000, Nigeria

Correspondence should be addressed to Awajiogak Anthony Ujile; ogakujile@yahoo.com

Received 29 December 2013; Accepted 23 February 2014; Published 25 March 2014

Academic Editor: Ahmet Z. Sahin

Copyright © 2014 A. A. Ujile and D. Amesi. This is an open access article distributed under the Creative Commons Attribution
License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly
cited.

This paper has applied thermodynamics principles to evaluate the reliability of 390 m3 /hr natural gas processing plant. The
thermodynamics equations were utilized in the evaluation, characterization, and numerical simulation of key process parameters
in natural gas liquid extraction plant. The results obtained show the comparison of the coefficient of performance, compression
ratio, isentropic work, actual work, electrical power requirements, cooling water consumption in intercoolers, compressor power
output, compressor capacity, and isentropic, volumetric, and mechanical efficiency of the two-stage refrigeration unit with a flash
gas economizer and these were compared with the designed specifications. The second law of thermodynamics was applied in
analyzing the refrigeration unit and the result shows that exergetic losses or lost work due to irreversibility falls within operating
limit that is less than 1.0%. Similarly, the performance of expansion turbine (expander) parameters was monitored and the results
indicate a considerable decrease in turbine efficiencies as the inlet gas pressure increases resulting in an increased power output of
the turbine leading to a higher liquefaction rate.

1. Introduction thermodynamics parameters are monitored daily in a gas

The production and availability of natural gas liquid depend
largely on the supply of raw natural gas from production
wellhead and the operating conditions of the process unit that
make up the extraction plant. Most gas processing plants are
faced with problems ranging from inadequate supply, poor
facility performance, and human factors. These problems can
lead to low productivity of natural gas liquids and reduction
in gas quality which could result in shutting down of the
plant. Poor facilities such as inadequate electricity supply
and processed water supply used in process equipment also
lead to intermittent operations and malfunction of process
equipment such as pumps, compressors, and valves if they are
not adequately checked.
Human factors may also result from the inability of
gas plant operators to monitor thermodynamics parameters
such as the pressure, flow rates, and temperature on process
equipment which could result in loss of data in control room
and unintended activation or deactivation of process devices
and reduce the plant efficiency. In spite of the fact that these
plant, there are problems of low gas feed inlet pressure and
insufficient gas flow rate. These have resulted in low volume of
natural gas liquids produced, the extracted natural gas liquids
not attaining the expected cryogenic temperature require-
ment, and variation in gas quality discharging from the outlet
of natural gas liquid extraction unit bottom product.
If the available inlet gas pressure is low, it can result
in compressor system suction pressure falling below atmo-
spheric pressure. This can also lead to air leakages into the
compressor system, contributing to pulsation, corrosion, and
low heating value of natural gas. In order to solve these prob-
lems, performance evaluation of the process units in natural
gas liquids extraction using thermodynamics principles is
necessary to ensure that these problems are minimized.
It is seen from literature survey that several papers have
been published focusing on thermodynamic analysis of a gas
turbine power plant.
Rahman et al. [1] and Taniguchi and Miyamae [2] carried
out the study on the effects of ambient temperature and
ambient pressure as well as temperature of exhaust gases on
2 Journal of Thermodynamics
performance of gas turbine. Khaliq and Kaushik [3] studied
the efficiency of a gas turbine cogeneration system with heat
recovery steam generator.
Keith and Kenneth [4] developed a new method of
applying overall plant material balance equation to determine
the performance of a natural gas processing plant. Jibril et al.
[5] studied the simulation of expansion turbine (expander)
for recovery of natural gas liquids from natural gas stream
gas using HYPRO TECH’s HYSYS process simulation soft-
ware. Donnelly et al. [6] carried out researches on process
simulation and optimization of cryogenic operations using
multistream brazed aluminum heat exchangers. Ganapathy
et al. [7] studied the energy analysis of operating lignite fired
thermal power plant. Design methodology for parametric
study and thermodynamic performance evaluation of natural
gas process plant has been developed. Refrigeration unit and
expansion turbine unit which are the major components
of the plant were evaluated. The expansion of natural gas
through an expansion turbine with efficiencies shows a very
good performance Ujile and Alawa [8]. The comparison
between the energy losses and the energy losses of the
components unit were investigated.
This paper examined the reliability of a gas plant which
is the ability of a plant to maintain a stable efficiency with
respect to time using thermodynamics equations.
2. Methodology/System Descriptions
2.1. Propane Refrigeration Unit. The simulation of process
units in propane refrigeration cycle involves the applications
of thermodynamics principles to the following.
(i) Calculate the amount of heat added to or removed
from process streams.
(ii) Estimate the power requirements for process equip-
ment such as pumps, compressors, and turbine.
(iii) Evaluate the performance of a flash separator at
various temperatures and pressures.
(iv) Determine the bubble and dew point temperature
associated with distillation and bottom products.
A systematic diagram of propane refrigeration cycle is
shown in Figure 1. The refrigerant passes through the scrub-
ber into the first stage compressor at 1.9 bar as saturated vapor
where it mixes up with the vapor from the economizer unit.
It is compressed to the inlet of the second stage compressor
at 2.5 bar and discharges at 5.0 bar into the condenser as
superheated vapor. It leaves the condenser at 4.7 bar and
enters the first expansion valve and from the expansion valve
into an economizer drum where it flashes at an intermediate
pressure of 3.3 bar. The vapour phase with the economizer at
the top mixes up the vapour from the first stage compressor,
while the liquid discharges at the bottom and enters the
second expansion valve into the chiller at a pressure of 2.5 bar.
The process gas (natural gas) flows inside the tubes connected
to the chiller at 41∘ C and countercurrently exchanges heat and
gives up its energy with the liquid refrigerant surrounding the
tubes. The refrigerant boils up and leaves the chiller space as
saturated vapor to be recompressed again.
2.2. Expansion Turbine Unit. A turbo expander or an expan-
sion turbine is a centrifugal or axial flow turbine through
which a high pressure gas is expanded to produce useful work
that is used to drive a compressor. Because work is extracted
from the expanding high pressure gas, the expansion is an
approximation by an isentropic process (a constant entropy
process).
In the process of producing work, the expander lowers
the bulk stream temperature which could result in partial
liquefaction of the bulk stream (natural gas).
A systematic diagram of an expansion turbine (expander)
is presented in Figure 2. The feed gas enters the gas treating
unit after which it is cooled firstly in a gas-to-gas heat
exchanger and secondly the propane chiller. The condensed
liquid is removed in a separator and the gas from the
separator is cooled further in the low temperature gas-to-gas
heat exchanger and fed into a second cooled separator. Gas
from the cooled separator expands through the expansion
turbine to the pressure at the top of the demethanizer which
varies from 100 to 450 bar. During the expansion, condensate
is formed and the expander lowers the pressure of the inlet gas
value to the demethanizer pressure of the range 100–450 bar.
Thermodynamics Performance Parameters of Propane Refrig-
eration Unit. The relevant parameters required for thermody-
namics performance evaluation of propane refrigeration of
natural gas may be considered as follows.
Coefficient of Performance. This is defined as the ratio of the
heat absorbed (𝑄in ) by the refrigerant while passing through
the chiller to the work input (𝑊in ) required compressing
the refrigerant in the compressor. This is mathematically
expressed as [9, 10]
𝑄in
COP = , (1)
𝑊in
but
𝑊in = 𝑊comp1 + 𝑊comp2
= (1 − 𝑋𝐺) (𝐻𝐵 − 𝐻𝐴) + 𝑀𝐶 (𝐻𝐸 − 𝐻𝐷,MIX ) ,
(2)
(1 − 𝑋𝐺) 𝑀𝐶 (𝐻𝐴 − 𝐻𝐼 )
COP = .
(1 − 𝑋𝐺) (𝐻𝐵 − 𝐻𝐴) + 𝑀𝐶 (𝐻𝐸 − 𝐻𝐷,MIX )
Refrigeration Capacity. The refrigeration capacity determines
the rate of circulation of the refrigerant which, in turn,
determines the design and size of various units such as
condenser, compressor, evaporator (chiller), and expansion
valves. This is expressed by the following equation:
𝑀𝐶 (𝐻𝐴 − 𝐻𝐼 )
𝑅𝑐 = KJ/ min . (3)
210
The mass flow rate of cooling water is calculated as follows:
𝑄
𝑀CW = . (4)
𝐶𝑝CW Δ𝑇
The overall performance of a compressor is affected mainly
by the inlet pressure and the interstage cooler efficiency.
Journal of Thermodynamics 3

Comp1
1.9 bar out 2.5 bar 5.0 bar Cond-Q
Mix Cond
Chiller Condenser out
out Mixer out
Comp1-hp Comp2-hp
Comp1 Comp2
3.3 bar
Chiller Economizer To econ JT-1
Chiller-Q
2.7 bar
JT-2 Econ
Chiller in liq

Figure 1: Process flow diagram of propane refrigeration of natural gas with application of Hysys software.

Recompressor

Exp-compressor
Expander (3)
First gas/
gas exchanger
Expander
separator
JT valve

Demethanizer
inlet

Inlet (1) (2)

gas Second gas/
Gas gas exchanger Residue gas
treating
to sales
Side exchanger Reboiler
Demethanized
plant product

Figure 2: Flow diagram of expander process.

The simulation of process units in propane refrigeration The fraction of refrigerant vaporized in the chiller is
resulted in loss of energy on the system. The second avail- determined from enthalpy balance as follows:
ability balance was applied to calculate the energy losses or
lost work due to irreversibility of the process. The thermody- 𝑀𝐶(𝐻𝐻)𝐿 = 𝑀𝐶𝑋𝑉 (𝐻𝐼 ) + 𝑀𝐶 (1 − 𝑋V ) (𝐻𝐼 )𝐿 , (9)
namics equations applied on each of the process units are as
follows [10]. where 𝑋V is the mole fraction of refrigerant that evaporates as
Compressor unit: it throttles to the economizer unit.
𝐿 𝑊 = 𝑀𝐶 [(𝐻𝐴 − 𝑇𝑜 𝑆𝐴 )] − (𝐻𝐵 − 𝑇𝑜 𝑆𝐵 ) − 𝑊𝐸 ; (5) Expansion Turbine Unit. The relevant thermodynamics
condenser unit: parameters applied in expansion turbine unit in a gas plant
are as follows.
𝐿 𝑊 = 𝑇𝑜 [𝑀𝐶 (𝑆𝐶 − 𝑆𝐵 )] + 𝑀CW 𝑆CW(out) − 𝑆CW(in) ,
(6) (i) Isentropic Turbine Efficiency. This is defined as the
𝐻𝐸 − 𝐻𝐹
𝑀CW = 𝑀𝐶 [ ]; ratio of turbine actual work output to the work output
𝐻CW(out) − 𝐻CW(in) that would be achieved if the process between the inlet
and outlet pressure was isentropic. By definition [11],
expansion valve:
𝐿 𝑊 = 𝑀𝐶𝑇𝑜 (𝑆𝐵 − 𝑆𝐶) , ℎ1 − ℎ2𝑎
𝜂𝐸 = . (10)
(7) ℎ1 − ℎ2,𝑆
𝐻 − 𝐻𝐷
𝐿 𝑊 = 𝑀𝐶𝑇𝑜 [(𝑆𝐴 − 𝑆𝐷) − ( 𝐴 )] .
𝑇𝑖
(ii) Isentropic and Actual Work. The isentropic work of a
Refrigerant chiller: the chiller is the unit where the turbine is the work done by the turbine during the
process gas (natural gas) gives up its energy to the liquid constant entropy whereas actual work is the gross
refrigerant. The refrigerating effect which is the amount of work of a turbine:
heat absorbed by refrigerant or removed from the refrigerated
space is expressed as 𝑊act = 𝑚 (ℎ2 − ℎ1 ) ,
(11)
𝑄in = (1 − 𝑋𝐺) 𝑀𝐶 (𝐻𝐴 − 𝐻𝐼 ) . (8) 𝑊is = −𝑚 (ℎ1 − ℎ2,𝑆 ) .
4 Journal of Thermodynamics

5.0 bar E
F 4.7 bar Condenser

n
sio
es
Expansion

pr
valve 1
Pressure (bar)

om
ec
tag
H m1 3.3 bar m2 D

ds
B

2n
G Economizer

our
ui
n
liq
sio

Expansion

vap
res
ted

valve 2
p

ted
ra

m
co
tu

ura
e
Sa

1.9 bar tag

ts

Sat
1 s
I Chiller A

2745.51
575.46

2716.7

2716.4
630,0

2704

2729
Enthalpy (kJ/kg)

Figure 3: Pressure enthalpy diagram of a propane refrigeration cycle.

(iii) Power Recovery. The expander gas power recovery
is the output power of the turbine list to drive the
compressor. By definition,
𝑃𝑔 = −𝜂𝑚 (ℎ1 − ℎ2,𝑆 ) .
(iv) Theoretical and Actual Discharge Temperature. The
discharge and actual temperatures of a turbine are
expressed by the following equations [11, 12]:
𝑝2 (𝑘−1)/𝑘
𝑇2󸀠 = 𝑇1 ( ) ,
𝑝1
𝑝 (𝐾−1)/𝐾
𝑇2 = 𝑇1 + 𝑇1 [( 2 ) − 1] 𝜂𝐸 .
𝑝1
The results obtained from the evaluation with the above
equations are shown in graphical form in Figures 3 and 4.
3. Results and Discussion
The results on the refrigeration unit of a gas plant were
obtained using the 𝑃-𝑆 and 𝑇-𝑆 diagrams.
The two-stage compression refrigeration system in Fig-
ures 3 and 4 operates with a pressure range of 1.9 and
5.0 bar. The refrigerant enters the first stage compressor at a
suction pressure of 1.9 bar with enthalpy and entropy values
of 2704 KJ/kg and 7.145 KJ/kg⋅K, respectively. It discharges
into a mixer where it mixes up with the vapor leaving the
top of the flash economizer. The refrigerant is compressed
to the second stage compressor operating with a suction
pressure of 2.5 bar with enthalpy and entropy values of
2716.4 KJ/kg and 7.052 KJ/kg⋅K, respectively, and discharges
at the condenser inlet pressure of 5.0 bar, where −17,386.7 J/kg
of heat is rejected to the surrounding. The enthalpy and
entropy values of the condenser as a saturated vapour at
a pressure of 4.7 bar were observed to be 630 KJ/kg and
(12) 1.8363 KJ/kg⋅K, respectively. The refrigerant is throttled to
a flash economizer at an intermediate pressure of 3.3 bar.
During flashing 0.0034 kg/s of vapor evaporates from the
economizer drum while 0.1305 kg/s of liquid is throttled to
the chiller at a pressure of 1.9 bar with enthalpy and entropy
values of 575.5 KJ/kg and 1.8545 KJ/kg⋅K, respectively. The
process gas (natural gas) countercurrently exchanges heat and
gives up its energy to the liquid refrigerant at a temperature
(13) of 41∘ C. The result of the two-stage compression refrigeration
is summarized in Table 1.
The process parameters of other auxiliary units in
propane refrigeration plant are shown in Table 2.
The energy balance of the propane refrigeration unit
obtained from the evaluation based on the equations high-
lighted for the analysis is shown in Table 3.
By the design conditions, the centrifugal compressors
used in compressing the refrigerant should operate with
a pressure ratio of 1.2 : 1 and 1.4 : 1, isentropic efficiency of
70–80%, volumetric efficiency of 60–89%, and mechanical
efficiency of 20–50%. By analytical method, the pressure ratio
was found to be 1.316 and 1.414; the isentropic efficiency was
found to be 48.56% and 51.97%; the volumetric efficiency was
found to be 55.0% and 46.7% for the first and second stage
compressors, respectively, while the mechanical efficiencies
are 57.7% and 46.51%, respectively. The refrigeration cycle was
operating with an overall coefficient of performance of 62.37
with a refrigerating capacity of 4,922.2 tons after examining
the performance of other auxiliary units within the systems.
Tables 1, 2, and 3 show values obtained from the evaluation.
Journal of Thermodynamics 5

SE = 6.822 kJ/kg K
E
hE = 2748.5 kJ/kg
SF = 1.8368

2nd compression
151.8 F

Stage
Condenser

Satu
rate
dv
Expansion
B SB = 7.052 kJ/kg K

apou
valve 1
SG = 1.8368 hB = 2716.4 kJ/kg
H hH = 575.5

r
Temperature T (∘ C)

137 D

1st compression
G Economizer C

liquid

stage
ated
Expansion
Satur
valve 2 SI = 1.8545
hI = 575.5
A SA = 7.145 kJ/kg K
119 hA = 2704 kJ/kg
I Chiller

Entropy (kJ/kg)

Figure 4: Temperature entropy diagram of a propane refrigeration cycle.

Table 1: Summary of two-stage compression refrigeration.

Parameters Units 1st stage compressor 2nd stage compressor

Suction pressure bar 1.9 2.5
Discharge pressure bar 2.5 5.0
Compression ratio — 1.316 1.414
Isentropic work of compression J/kg 20,644.25 22,094.91
Actual work of compression J/kg 20,644.25 21,872.85
Isentropic efficiency % 48.56 51.98
Mechanical efficiency % 20.71 46.51
Volumetric efficiency % 55.0 46.7
Actual power requirement KW 0.0969 0.0960
Cooling water consumption in intercoolers m3 /s 7.2612 19.282
Compressor capacity m3 /s 2.1566 2.1096
Work input in comp 1 and comp 2 J/kg 273.14 273.14
Work output J/kg 1197.89 2414.11

The Kelvin-Planck statement of the second law of thermody-
namics tells us that it is impossible to have a heat engine that
will convert all the heat received from the high temperature
source, 𝑄𝐻, into useful work in a thermodynamic cycle. It
is necessary to reject part of the received heat to the low
temperature source, 𝑄𝐿 . In other words, it is impossible to
have a 100% efficiency heat engine as corroborated by Kumar
et al. [13] and José and Simões-Moreira [14].
4. Conclusion
The following recommendations are highlighted to
ensure optimum efficiency and reliability of NGL plant.
(i) The feed gas must be free from CO2 and water. This
affects plant efficiency and operations if not properly
checked by freezing the fittings, valves, and other
associated equipment.
(ii) The inlet strainer differential pressure must not be
high; otherwise the expander will trip off on high
differential pressure.

The thermodynamics equations were applied to construct (iii) The refrigeration unit must be operated within the
Figures 3 and 4 which determine the performance of the operating and design conditions to avoid overfreezing
plant. The recorded efficiencies ranging from 63.92% to or warming of the demethanizer column.
77% have shown that the overall performance has deviated (iv) There is need for proper insulation of piping system
from the design efficiency. This condition may increase the within the NGL extraction plant. The reason is not
operational cost of the plant. to allow the surrounding heat to enter the system,
6 Journal of Thermodynamics

Table 2: Process parameters of other auxilliary units.

Parameters Unit Condenser Economizer Expansion valve 1 Expansion valve 2 Refrigerant chiller
Suction pressure bar 5.0 3.3 4.7 3.3 2.3
Discharge pressure bar 4.7 — 3.3 1.9 1.9
Heat load J/kg −17,386.7 5733.78 — — 17,036.04
Mass flow rate of kg/s — 0.0034 — — —
vapor—economizer
Mass flow rate of kg/s — 0.1305 — — —
liquid—economizer
Mass flow rate of cooling kg/s 6.72 — — — —
water—condenser
Joule Thompson coefficient — — — 8.57 12.86 —
Mole fraction of liquid remaining — 0.035 0.00014
in chiller
Mole fraction of vapor — 0.025 0.025 — 0.045
evaporated in chiller
Mass flow rate of kg/s 0.1339
liquid—condenser accumulator

Table 3: Energy balance propane refrigeration unit.

Process units Energy gain (KJ/kg) Energy lost (KJ/kg) % of lost work
Compressor 1 12.30 −334.28 −0.015
Compressor 2 32.11 −501.45 −0.023
Condenser — 12483.89 0.06
Expansion valve JT-1 — 12495.54 0.06
Expansion valve JT-2 — −1435547.8 6.62
Economizer drum 5733.78 — —
Refrigerant chiller 17036.04 −1242710.43 −5.73
Total 22814.23 216981.07 0.972

thereby warming the system, and there may be freez-
ing out of the plant.
(v) Proper sizing of the process line using the various line
balance methods to compare the amount of natural
gas entering the process plant with the amount put in
should be adopted at the design stage of the process
plant.
Nomenclature
𝐶𝑝CW : The specific heat capacity of
water
𝐻𝐴 , 𝐻𝐵 , 𝐻𝐷,mix , 𝐻𝐸 and 𝐻𝐼 : The enthalpies of refrigerant
at compressor inlet (KJ/kg),
outlet (KJ/kg), vapor mixture
coming from compressor and
economizer units (KJ/kg), at
the condenser inlet (KJ/kg),
and at the inlet of the
refrigerant chiller (KJ/kg),
respectively
ℎ1 , ℎ2𝑎 , ℎ2,𝑆 : The enthalpies of the gas
expander inlet, gas expander
outlet, and at the exit pressure
but at the inlet entropy
(KJ/kg), respectively
𝑘: The specific heat capacity ratio
of gas to expander
𝐿 𝑤: The lost work or rate of
irreversibility of refrigerant
(KJ/kg)
𝑚: The mass flow rate of the gas to
expander (kg/s)
𝑀𝑐 : The refrigerant circulation rate
𝑀CW : The mass flow rate of cooling
water (kg/s)
𝑃1 and 𝑃2 : The inlet and outlet gas
pressure to expander (bar)
respectively
𝑄: The amount of heat removed in
the intercoolers
𝑆𝐴 , 𝑆𝐵 , 𝑆𝐶, 𝑆𝐷: The entropies of refrigerant at
compressor inlet (KJ/kg⋅K),
compressor outlet (KJ/kg⋅K),
leaving the economizer
(KJ/kg⋅K), and vapor mixture
(KJ/kg⋅K), respectively
𝑆CW(in) , 𝑆CW(out) : The entropies of inlet cooling
water and outlet cooling water,
respectively
𝑇𝑜 : The dead state temperature
Journal of Thermodynamics 7

𝑇1 : The inlet gas temperature to [13] A. Kumar, S. S. Kachhwaha, and R. S. Mishra, “Thermodynamic
expander (∘ C) analysis of a regenerative gas turbine cogeneration plant,”
𝑇2 : The actual gas temperature at Journal of Scientific and Industrial Research, vol. 69, no. 3, pp.
expander outlet (∘ C) 225–231, 2010.
󸀠
𝑇2 : The theoretical gas tempera- [14] R. José and Simões-Moreira, “Thermal Power Plant Perfor-
ture at expander outlet (∘ C) mance Analysis,” 2012, http://www.springer.com/978-1-4471-
2308-8.
𝑊𝐸 : The electrical power require-
ment to compressor (KW)
𝑋𝐺: The mole fraction of vapor
leaving the economizer unit
Δ𝑇: The temperature difference
within the system boundary
𝜂𝐸 : The expander efficiency
𝜂𝑚 : The mechanical efficiency.

Conflict of Interests
The authors declare that there is no conflict of interests
regarding the publication of this paper.

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International Journal of International Journal of

Statistical Mechanics
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Optics
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Thermodynamics
Physics Advances in
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